Manual Disconnect Mechanism with Interlock Resistor for High Voltage Battery Isolation
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Solution Overview
Problem
Existing manual disconnects for high voltage batteries in electric vehicles do not provide a safe and reliable method to isolate the battery circuit, risking damage to vehicle systems and injury to technicians or first responders during service or after accidents.
Innovation Solution
A manual disconnect mechanism with a base, interlock connector, and plug assembly that allows for safe disconnection of the battery circuit by moving between disconnected, primary circuit engaged, and interlock positions, utilizing a fuse and interlock resistor assembly to ensure safe current flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manual disconnect is provided for high voltage batteries, then safety during service and emergency situations is improved, but device complexity increases due to the interlock mechanism and multiple positions
Solution Approach 1:
The manual disconnect is divided into separate functional components: a base with primary terminals, a plug assembly with fuse terminals, and an interlock mechanism with resistor assembly. This segmentation allows each component to perform its specific function independently while maintaining overall system safety and reliability without excessive complexity.
Solution Approach 2:
An interlock mechanism with resistor assembly acts as an intermediary between the plug assembly and the primary circuit. This intermediary component ensures that the disconnect operation follows a safe sequence, preventing direct exposure to high voltage until proper isolation is achieved, thereby enhancing safety without requiring overly complex control systems.
2Reliability
If the plug assembly is moved to the interlock position to ensure safety, then protection of vehicle systems and personnel is improved, but the circuit remains engaged longer increasing loss of time
Solution Approach 1:
The interlock mechanism performs preliminary safety verification before allowing full circuit engagement or disengagement. The resistor assembly provides preliminary isolation, ensuring that safety conditions are met before the plug assembly can be moved to final positions, thereby preventing dangerous situations without causing unnecessary delays.
Solution Approach 2:
The plug assembly is designed to move dynamically between three distinct positions (disconnected, primary circuit engaged, and interlock). This dynamic positioning allows the system to adapt to different operational states, providing safety when needed while minimizing circuit interruption time when the circuit needs to remain active, thus balancing protection with operational efficiency.
3Reliability
If the plug assembly moves between multiple positions for safe disconnection, then reliability of circuit isolation is improved, but ease of operation deteriorates due to complex movement sequence
Solution Approach 1:
The disconnect mechanism is segmented into distinct positional states (disconnected, primary circuit engaged, and interlock positions), with each position providing a specific level of isolation. This segmentation ensures reliable circuit isolation at each stage while maintaining a logical progression that guides the operator through the correct sequence, balancing reliability with operational simplicity.
Data Source
AI summary
A manual disconnect for an electric circuit includes a base with primary terminals and an interlock connector. A plug assembly includes fuse terminals and an interlock resistor assembly. The plug assembly is movable relative to the base between a disconnected position, wherein the fuse terminals are not engaged with respective primary terminals, and a primary circuit engaged position, wherein the fuse terminals are engaged with respective primary terminals. The plug assembly is also movable to an interlock position, wherein the interlock connector is engaged with the interlock resistor assembly. The plug assembly is moved in an insertion to move the plug assembly from the disconnected position to the primary circuit engaged position, and is rotated about an axis to move from the primary circuit engaged position to the interlock position.